Power supply device and method for manufacturing the same

Abstract

The purpose of the present invention is to avoid erroneous fusing of a fuse during assembly and increase workability.　Provided is a method for manufacturing a power source device (100) comprising a battery unit (2) in which a plurality of secondary battery cells (1) are at least connected in series and which is provided with a low-voltage-side battery-side ground (21G) and a high-voltage-side battery-side output (21H) that are connected in said series, and a circuit unit (3) that is electrically connected to the battery unit (2), controls charging and discharging, and is provided with an overvoltage sensing fuse for detecting overvoltage and fusing. The method for manufacturing includes: a step for respectively connecting, to one or more circuit-side intermediate terminals (41) provided to the circuit unit (3), one or more battery-side intermediate terminals (21) electrically connected to the intermediate potential of at least some of the plurality of secondary battery cells (1) connected in series, which are provided to the battery unit (2), in a state where a detachable lead member (50) for connecting the overvoltage sensing fuse and the battery-side output (21H) has been detached; and a step for fixing the lead member (50) to the circuit unit (3) and connecting the overvoltage sensing fuse and the battery-side output (21H).

Description

[Technical Field]

[0001] The present invention relates to a power supply device and a method for manufacturing the same. [Background technology]

[0002] Power supply devices with many secondary battery cells connected in series and parallel are used as backup power sources for servers, as stationary power storage devices for homes, offices, and factories, and also as power sources for driving vehicles such as hybrid cars, electric cars, electric carts, and electric scooters, as well as for power-assisted bicycles and power tools. These power supply devices aim to achieve high output by connecting many secondary battery cells in series.

[0003] For example, a power supply device 600 shown in the exploded perspective view of Figure 6 includes a battery unit 602 that holds multiple secondary battery cells 601, and a circuit board 604 that is equipped with a control circuit that controls the charging and discharging of the secondary battery cells 601 and an overvoltage detection fuse.

[0004] The power supply device also includes an overvoltage detection fuse that detects and blows an overvoltage to protect the secondary battery cells from overvoltage. A circuit diagram of a power supply device equipped with such an overvoltage detection fuse is shown in FIG. 7. As shown in this diagram, the power supply device 600 connects a battery unit 602 and a circuit unit 603. The battery unit 602 connects multiple secondary battery cells 601 in series and is provided with a battery-side ground terminal 621G and a battery-side positive terminal 621H. Meanwhile, the circuit unit 603 includes a connection terminal 641 for connection to the battery unit 602, external terminals 648 and 649, and conductive paths connecting the connection terminal 641 to the external terminal 648 and the connection terminal 641 to the external terminal 649. In the circuit unit 603, a fuse module 634, a charging switching element 644, and a discharging switching element 645 are inserted in the positive-side conductive path connecting the connection terminal 640 to the external terminal 648. The fuse module 634 is configured by combining two thermal fuses 634a, 634a connected in series with a heating resistor 634b having one end connected to the connection point between the thermal fuses 634a and 634a. The other end of the heating resistor 634b is connected to a ground-side conductive path connecting the connection terminal 641 and the external terminal 649 via a heating resistor switching element 650. Note that the other end of the heating resistor 634b does not necessarily have to be connected to the ground side, and may be connected to an intermediate potential of the secondary battery cell 601 depending on the circuit configuration. In addition, various switching elements such as a MOSFET can be used as the heating resistor switching element as appropriate.

[0005] In the circuit unit 603, the connection terminals 641 are each connected to a control unit 646, which monitors the voltage of each secondary battery cell 601. The control unit 646 is also connected to the gate of the heating resistor switching element 650, and if it determines that the voltage of the secondary battery cell 601 is in an abnormal state such as an overvoltage, it turns on the heating resistor switching element 650, heating the heating resistor 634b and melting the thermal fuse 634a.

[0006] When assembling such power supplies, a random connection without specifying the order of connection between the power supply and the series-connected parts of the cell blocks is required for ease of assembly. However, when connecting a circuit board containing an overvoltage detection fuse to a series-connected part that connects multiple secondary battery cells in series, random connection, including the circuit parts that form the fuse path including the overvoltage detection fuse, can result in the overvoltage detection fuse being accidentally blown due to the momentary detection action of the overvoltage protection IC during connection. In particular, as shown in Figure 6, when connecting a circuit unit to a battery unit, it is difficult to control which of the multiple terminals will touch first, and depending on the connection method, the overvoltage detection fuse may be accidentally blown during assembly. For this reason, random connection is not possible. Instead, the circuit board and each cell series-connected part must be connected in order, starting with the circuit-side ground and the battery-side ground, and proceeding toward the high-voltage side. This required a specific connection order, which resulted in poor workability and time-consuming work. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Application Laid-Open No. 2014-102968 Summary of the Invention [Problem to be solved by the invention]

[0008] An object of the present invention is to provide a power supply device and a method for manufacturing the same that can prevent erroneous fuse blowout during assembly and improve workability.

[0009] To achieve the above object, a first aspect of the present invention provides a method for manufacturing a power supply device including a battery unit including a plurality of secondary battery cells connected in series, the battery unit including a battery-side ground on the low-voltage side of the series-connected secondary battery cells and a battery-side output on the high-voltage side of the series-connected secondary battery cells, and a circuit unit electrically connected to the battery unit, controlling charging and discharging, and including an overvoltage detection fuse that detects and blows an overvoltage, the method comprising the steps of: connecting one or more battery-side intermediate terminals electrically connected to an intermediate potential of at least some of the series-connected secondary battery cells to one or more circuit-side intermediate terminals provided on the circuit unit while detaching detachable lead members connecting the overvoltage detection fuse to the battery-side output; and fixing the lead members to the circuit unit and connecting the overvoltage detection fuse to the battery-side output. This allows the overvoltage detection fuse of the circuit unit to be electrically isolated by detaching the detachable lead members during assembly of the power supply device, thereby preventing the overvoltage detection fuse from being accidentally blown when connecting the battery-side intermediate terminal of the battery unit to the circuit-side intermediate terminal of the circuit unit. Furthermore, by realizing random connection between the battery-side intermediate terminals and the circuit-side intermediate terminals, the workability of connecting the circuit unit and the battery unit can be improved, and production efficiency can be improved.

[0010] In addition, in a second aspect of the present invention, there is provided a method for manufacturing a power supply device, wherein the circuit unit includes an overvoltage protection circuit that monitors an overvoltage of at least one of the plurality of secondary battery cells, and the overvoltage protection circuit is configured to blow the overvoltage detection fuse when it detects an overvoltage of the secondary battery cell. This provides the advantage that, even if an overvoltage detection signal is mistakenly issued when electrically connecting the overvoltage protection circuit during assembly of the power supply device, the overvoltage detection fuse will not blow because it is electrically isolated, thereby protecting the power supply device from unintended damage during assembly.

[0011] Furthermore, a third aspect of the present invention provides a power supply device including a battery unit including a plurality of secondary battery cells connected in series and including a battery ground on a low-voltage side of the series-connected secondary battery cells and a battery output on a high-voltage side, and a circuit unit connected to the battery unit, wherein the battery unit includes one or more battery intermediate terminals electrically connected to an intermediate potential of at least some of the series-connected secondary battery cells, and the circuit unit includes one or more circuit intermediate terminals connected to at least one of the secondary battery cells via the one or more battery intermediate terminals, an overvoltage detection fuse connected to the battery output and configured to detect and blow an overvoltage of the plurality of secondary battery cells, and a detachable lead member interposed between the overvoltage detection fuse and the battery output. With this configuration, the detachable lead member can be removed during assembly of the power supply device to electrically isolate the overvoltage detection fuse of the circuit unit, thereby preventing the overvoltage detection fuse from being accidentally blown when connecting the battery intermediate terminal of the battery unit to the circuit intermediate terminal of the circuit unit. Furthermore, by realizing random connection between the battery-side intermediate terminals and the circuit-side intermediate terminals, the workability of connecting the circuit unit and the battery unit can be improved, and production efficiency can be improved.

[0012] Furthermore, in a power supply device according to a fourth aspect of the present invention, in any of the above aspects, the circuit unit includes an overvoltage protection circuit that monitors overvoltage of the plurality of secondary battery cells, and the overvoltage protection circuit is configured to blow the overvoltage detection fuse when it detects an overvoltage of the secondary battery cell. With this configuration, even if an abnormality is mistakenly detected when electrically connecting the overvoltage protection circuit during assembly of the power supply device, the overvoltage detection fuse can be prevented from being blown, providing the advantage of protecting against unintended damage during assembly.

[0013] Furthermore, in the power supply device according to a fifth aspect of the present invention, in any one of the above aspects, the lead members are configured as metal bus bars, which makes it possible to easily attach and detach the lead members, through which a large current flows, to the circuit unit.

[0014] Furthermore, in the power supply device according to a sixth aspect of the present invention, in any one of the above aspects, the lead member includes a lead wire with a connector or a wire clip.

[0015] Furthermore, a seventh aspect of the present invention provides a power supply device comprising: a battery unit in which a plurality of secondary battery cells are connected at least in series, the battery unit having a battery-side ground on the low-voltage side of the series-connected secondary battery cells and a battery-side output on the high-voltage side; and a circuit unit connected to the battery unit, wherein the battery unit has one or more battery-side intermediate terminals electrically connected to an intermediate potential of at least some of the plurality of series-connected secondary battery cells; the circuit unit has one or more circuit-side intermediate terminals connected to at least one of the plurality of secondary battery cells via the one or more battery-side intermediate terminals; and an overvoltage detection fuse connected to the battery-side output and detecting and blowing an overvoltage of the plurality of secondary battery cells, the overvoltage detection fuse comprising two thermal fuses connected in series; and a heating resistor having one end connected to a connection point of the thermal fuses and generating heat when current is applied to blow the thermal fuse; and the overvoltage detection fuse is configured as a unit that is detachable from the circuit unit. With the above configuration, the overvoltage detection fuse of the circuit unit can be electrically isolated by removing the detachable lead member when assembling the power supply device, preventing the overvoltage detection fuse from accidentally blowing when connecting the battery-side intermediate terminal of the battery unit to the circuit-side intermediate terminal of the circuit unit. Furthermore, by realizing random connection of the battery-side intermediate terminal and the circuit-side intermediate terminal, the workability of connecting the circuit unit and the battery unit can be improved, thereby improving production efficiency. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is an exploded perspective view showing a power supply device according to a first embodiment of the present invention. [Figure 2] 1 is a circuit diagram showing a power supply device according to a first embodiment of the present invention. [Figure 3] 3 is a circuit diagram showing the state in which the lead members are removed during assembly of the power supply device of FIG. 2. FIG. [Figure 4] FIG. 1 is a plan view of a power supply device according to a first embodiment. [Figure 5] FIG. 10 is a circuit diagram showing a state in which a fuse unit is removed during assembly of a power supply device according to a second embodiment. [Figure 6] FIG. 10 is an exploded perspective view showing a conventional power supply device. [Figure 7] FIG. 1 is a circuit diagram showing a power supply device provided with a conventional overvoltage detection fuse. DETAILED DESCRIPTION OF THE INVENTION

[0017] Embodiments of the present invention will be described below with reference to the drawings. However, the embodiments described below are merely examples for embodying the technical concept of the present invention, and the present invention is not limited to these. Furthermore, this specification in no way specifies the components set forth in the claims as components of the embodiments. The dimensions, materials, shapes, and relative positions of components described in the embodiments are not intended to limit the scope of the present invention, and are merely illustrative unless otherwise specified. The size and relative positions of components shown in the drawings may be exaggerated for clarity. Furthermore, in the following description, the same names and symbols indicate identical or similar components, and detailed descriptions will be omitted as appropriate. Furthermore, the elements constituting the present invention may be configured with the same components, so that one component serves multiple functions, or conversely, the function of one component may be shared by multiple components.

[0018] The power supply device of the present invention can be used for a variety of purposes, such as a backup power supply for servers, a power supply mounted on electric vehicles such as hybrid cars and electric automobiles to supply power to the drive motor, a power supply for storing power generated by natural energy sources such as solar power and wind power, or a power supply for storing late-night power, and is particularly suitable for use in large power and large current applications. Below, we will explain a power supply device used as a backup power supply for a server as one embodiment of the present invention. [Embodiment 1]

[0019] An exploded perspective view of a power supply device 100 according to a first embodiment of the present invention is shown in Figure 1. The power supply device 100 shown in this figure includes a battery unit 2 and a circuit unit 3 mounted on one surface of the battery unit 2. The battery unit 2 holds a plurality of secondary battery cells 1. The circuit unit 3 includes a circuit board 40. (Secondary battery cell 1)

[0020] Each secondary battery cell 1 is a cylindrical secondary battery cell with a cylindrical outer can. The cylindrical secondary battery cell 1 has electrode surfaces on both end faces. The multiple secondary battery cells 1 are connected at least in series. Preferably, the series-connected secondary battery cells 1 are further connected in parallel. The output of a battery assembly composed of secondary battery cells 1 including those connected in series is output from a power supply device 100. The secondary battery cells 1 are cylindrical lithium-ion secondary batteries. However, the power supply device of the present invention does not limit the secondary battery cells to cylindrical batteries or lithium-ion secondary batteries. Any rechargeable battery, such as nickel-metal hydride battery cells, can be used as the battery cells. (Battery holder 10)

[0021] The battery unit 2 is a component for holding multiple secondary battery cells 1. This battery unit 2 includes a battery holder 10 with a cylindrical battery holding section into which cylindrical secondary battery cells 1 can be inserted. The battery holder 10 in Figure 1 has two battery holding sections, with the cylindrical centers of the upper and lower battery holding sections offset from each other to reduce the overall thickness. The battery holder 10 is made of a material with excellent insulating and heat-resistant properties, such as polycarbonate ABC resin.

[0022] The battery holder 10 is divided into multiple sub-holders that sandwich the rechargeable battery cell 1 from both sides. The middle portion of the rechargeable battery cell 1 is exposed from the sub-holders. With the rechargeable battery cell 1 sandwiched between the sub-holders, lead plates 20 are fixed to the side of the battery holder 10, and the rechargeable battery cell 1 and the lead plates 20 are welded together. Lead positioning guides that follow the outline of the lead plates 20 are formed on the side of the battery holder 10 to position the lead plates 20 in a predetermined position.

[0023] The battery holder 10 also includes multiple lead plates 20 and a battery-side ground terminal 30. The multiple lead plates 20 include a battery-side intermediate terminal 21. The battery-side intermediate terminal 21 is electrically connected to at least one of the multiple secondary battery cells 1. (Lead plate 20)

[0024] Each lead plate 20 is arranged on a side surface of the battery holder 10 and is connected to the electrode surfaces of multiple secondary battery cells 1. The lead plates 20 are used to connect multiple secondary battery cells 1 in series and parallel. In particular, when using high-capacity secondary battery cells 1 such as lithium-ion secondary batteries, the state of each secondary battery cell 1 can be determined by detecting the potential of each lead plate 20, thereby determining the voltage of the assembly of secondary battery cells 1 connected in parallel to this lead plate 20. In this example, six secondary battery cells 1 are connected in parallel, and seven sets of these are connected in series, resulting in a battery assembly consisting of a total of 42 secondary battery cells 1.

[0025] The multiple lead plates 20 electrically connect the electrode terminals of adjacent secondary battery cells 1. Of the multiple lead plates 20, the lead plate on the ground side of the total output of the battery connection assembly in which multiple secondary battery cells 1 are electrically connected in series is designated as ground lead plate 20G, and this ground lead plate 20G is connected to the battery-side ground terminal 30. The lead plate on the HIGH side of the total output of the battery connection assembly is designated as output lead plate 20H.

[0026] The battery-side ground terminal 30 is connected to the ground side of the total output of the multiple secondary battery cells 1 electrically connected in series and / or parallel. This battery-side ground terminal 30 is drawn out from the battery holder 10.

[0027] Furthermore, the upper surface of the battery holder 10 serves as a mounting surface 11 on which a circuit board 40 is placed. A frame for holding the circuit board may be formed on the board mounting surface. Alternatively, a board holder for holding the circuit board may be provided separately. (circuit board 40)

[0028] The circuit board 40 is placed on the mounting surface 11. Electronic circuits mounted on the circuit board 40 include a voltage detection circuit that detects the intermediate potential of the battery assembly in which secondary battery cells 1 are connected in series or parallel, a control circuit that controls charging and discharging, and a safety circuit. The intermediate potential of the multiple secondary battery cells 1 connected in series that make up the battery assembly is detected from the potential of the lead plates 20 and input to the voltage detection circuit.

[0029] 2 shows a circuit diagram of this power supply device 100. The power supply device 100 shown in this figure comprises a battery unit 2 and a circuit unit 3. (Battery unit 2)

[0030] The battery unit 2 has multiple secondary battery cells 1. The multiple secondary battery cells 1 are connected in series. Although not shown in FIG. 2 for simplicity, the series-connected battery assemblies can also be connected in parallel. The battery unit 2 also has a low-voltage battery ground 21G and a high-voltage battery output 21H connected in series. The battery ground 21G is connected to a ground lead plate 20G, and the battery output 21H is connected to an output lead plate 20H. The battery unit 2 also has one or more battery-side intermediate terminals 21 electrically connected to intermediate potentials of at least some of the multiple series-connected secondary battery cells 1.

[0031] As shown in FIG. 2, the battery unit 2 has a negative battery ground 21G connected to a circuit ground terminal 46 of the circuit unit 3, and a positive battery output 21H connected to a circuit HIGH terminal 41H. The battery intermediate terminal 21 is connected to a control unit 43 via a circuit intermediate terminal 41. The circuit intermediate terminal 41 is connected to a negative external terminal 49 via a conductive path. The battery output 21H is connected to a positive external discharge terminal 47 and an external charge terminal 48 via conductive paths. A discharge path DP of the battery unit 2 is formed between the battery output 21H and the external discharge terminal 47. Discharge control via the discharge path DP is performed by a higher-level power supply or the system side.

[0032] A fuse module 34, a charging switching element 44, and a discharging switching element 45 are inserted in series in a charging / discharging path CP that connects the connection terminal and the external charging terminal 48. The gates of the charging switching element 44 and the discharging switching element 45 are connected to the control unit 43.

[0033] In the example of Figure 2, a discharge path DP connected to the external discharge terminal 47 is provided for the battery-side output 21H, separate from the charge / discharge path CP connected to the external charge terminal 48. For example, in a power supply device for a backup power storage server, where the discharge path is a large current of 100A or so, providing a discharge path DP separate from the charge / discharge path CP makes it easier to discharge large currents. However, the present invention is not limited to configurations that provide a separate path dedicated to discharge, and can also be applied to configurations that do not have a discharge path. In other words, the discharge path DP may be omitted from the circuit example of Figure 2. For example, if the discharge current is relatively small, the expensive and large overvoltage detection fuse required for large currents can be omitted, resulting in a simpler, more compact, and less expensive circuit configuration. In this case, the overvoltage detection fuse is placed in the charge / discharge path CP.

[0034] The fuse module 34 is composed of thermal fuses 34a, 34a connected in series with each other, and a heating resistor 34b having one end connected to the connection point between the thermal fuses 34a and 34a. The other end of the heating resistor 34b in the fuse module 34 is connected to the control unit 43. It may also be connected to a conductive path connecting the battery-side intermediate terminal 21 and the external terminal 49 via a heating resistor switching element. In this case, the gate of the heating resistor switching element is connected to the control unit 43, and the control unit 43 controls the heating resistor switching element to regulate the operation of the heating resistor 34b. (Circuit unit 3)

[0035] The circuit unit 3 includes a circuit board on which multiple electronic components that constitute a charge / discharge circuit and an overvoltage protection circuit are mounted. The circuit unit 3 includes a circuit-side intermediate terminal 41, an external discharge terminal 47, an external charge terminal 48, a control unit 43, a fuse module 34, lead members 50, a charge switching element 44, a discharge switching element 45, and a second overvoltage protection circuit 43B. The circuit-side intermediate terminal 41 is connected to at least one of the multiple secondary battery cells 1 via one or more battery-side intermediate terminals 21.

[0036] The control unit 43 controls the charging switching element 44 and the discharging switching element 45 to charge and discharge the battery unit 2. The charging switching element 44 and the discharging switching element 45 are preferably made of field-effect transistors (FETs). The FETs may be p-channel or n-channel, as shown in FIG. 2 and other figures. While the example shown in FIG. 2 and other figures illustrates a configuration in which the charging FET is located on the left and the discharging FET is located on the right, with the drain terminals of these FETs connected together, this is not limiting. For example, the discharging FET may be located on the left and the charging FET on the right, with the source terminals of these FETs connected together. Furthermore, additional elements, such as resistors, may be inserted between the charging FET and the discharging FET as needed. Additionally, the charging switching element 44 and the discharging switching element 45 may be made of multiple FETs. For example, multiple FETs may be connected in parallel to use elements with lower rated currents.

[0037] The control unit 43 also implements an overvoltage protection circuit, which monitors the intermediate potential of multiple series-connected secondary battery cells 1 via the battery-side intermediate terminal 21 and the circuit-side intermediate terminal 41, and when it reaches a predetermined voltage, it determines that this is an overvoltage and activates the fuse module 34 to cut off the current.

[0038] Furthermore, the circuit unit 3 includes a second overvoltage protection circuit 43B. The second overvoltage protection circuit 43B is separate from the overvoltage protection circuit of the control unit 43 described above, and enhances safety by monitoring the charging current when charging the battery unit 2. This second overvoltage protection circuit 43B may be omitted. (Fuse module 34)

[0039] The fuse module 34 functions as an overvoltage detection fuse that detects and blows an overvoltage in the secondary battery cell 1. The fuse module 34 includes two thermal fuses 34a, 34a connected in series, and a heating resistor 34b, one end of which is connected to the junction of the thermal fuses 34a and generates heat when current is applied, thereby blowing the thermal fuse 34a. The heating resistor 34b is controlled by the control unit 43 and the second overvoltage protection circuit 43B. For example, a heating resistor switching element such as a MOSFET may be connected to the heating resistor 634b to operate the heating resistor 634b. In this case, the other end of the heating resistor switching element may be connected to a ground-side conductive path or to an intermediate potential of the battery unit 2, depending on the required drive voltage, withstand voltage, etc. (Lead member 50)

[0040] The lead member 50 is interposed between the fuse module 34 and the battery-side output 21H. This lead member 50 is detachable from the circuit unit 3. By removing the lead member 50 from the circuit unit 3, the fuse module 34 can be electrically isolated as shown in FIG. 3. This allows the detachable lead member 50 to be removed when assembling the power supply device 100, thereby preventing the overvoltage protection circuit or the like from malfunctioning and erroneously blowing the overvoltage detection fuse when connecting the battery-side intermediate terminal 21 of the battery unit 2 and the circuit-side intermediate terminal 41 of the circuit unit 3. Furthermore, realizing random connection between the battery-side intermediate terminal 21 and the circuit-side intermediate terminal 41 improves the ease of connecting the circuit unit 3 and the battery unit 2 and improves production efficiency.

[0041] The fuse module 34 interposed in the charge / discharge path CP is mounted on a circuit board 40. A lead member 50 connects the fuse module 34 and the discharge path DP on the circuit board 40. The lead member 50 can be configured from a lead wire, a metal bus bar, or the like.

[0042] Furthermore, when the overvoltage detection fuse is large, such as when the current value is large, a fuse module containing the overvoltage detection fuse may be prepared as a separate component rather than being mounted on the circuit board. For example, a fuse module may be configured as a unit in which the overvoltage detection fuse is housed in a case. The present invention is also applicable to such cases, and the circuit board 40 and fuse module 34 are connected by lead members 50. For example, in the example of FIG. 4, the fuse module 34 is mounted on a substrate separate from the circuit board, and the two are electrically connected by lead members 50 formed from bus bars. This configuration allows the lead members 50, through which a large current flows, to be easily attached and detached from the circuit unit 3.

[0043] Furthermore, the lead member 50 is not limited to such a bus bar, but may be formed of a flexible member such as a lead wire with a connector or a wire clip. The fuse module 34 can also be mounted on a circuit board. In this case, it is effective to form the lead member 50 from a flexible member that is easy to attach and detach. In this specification, the term "detachable" does not necessarily mean that the lead member 50 can be completely physically separated; it is sufficient to take a form that can temporarily physically interrupt the flow of current. For example, in the case of the lead wire or wire clip described above, one end may be fixed to one of the fuse module or battery-side output terminals, and the other end may be left as a free end and connected to the other of the fuse module or battery-side output terminals by means of engagement, locking, clamping, insertion / removal, screwing, or the like using a clip, round terminal, connector, or the like. Alternatively, one end of the lead wire may be fixed, and the other end may be locked to a notch in a lead plate, or the like. Alternatively, a switch that can be opened or closed may be provided for physical interruption. [Manufacturing method of power supply unit]

[0044] The manufacturing method for this power supply device is described below. First, with the detachable lead members 50 removed, the circuit unit 3 is connected to the battery unit 2. For example, as shown in FIG. 1, the circuit unit 3 is placed on one side of the battery unit 2, and the battery-side intermediate terminals 21 of the battery unit 2 are connected to the circuit-side intermediate terminals 41 of the circuit unit 3. The lead members 50 are then fixed to the circuit unit 3, and the overvoltage detection fuse and the battery-side output 21H are connected. This allows the circuit unit 3, including the overvoltage detection fuse, to be randomly connected to the series battery array almost simultaneously, without accidentally blowing the overvoltage detection fuse, allowing the circuit board to be attached. Furthermore, by achieving random connection, the board and cell block can be connected in a short time, improving production efficiency. [Embodiment 2]

[0045] Furthermore, in the present invention, the lead member 50 connecting the fuse module 34 and the battery-side output 21H may be detachable, or the fuse module itself may be detachable. Such a configuration is shown in the circuit diagram of a power supply device 200 according to a second embodiment in FIG. 5. In the power supply device 200 shown in this figure, components similar to those in the first embodiment are designated by the same reference numerals and will not be described in detail. In the power supply device 200 shown in this figure, instead of lead members, the fuse module is a modular fuse unit 34' that is detachable from the circuit unit 3. Even with this configuration, power supply device 200 can still be physically shut off from the thermal fuse 34a during assembly. Therefore, even if the overvoltage protection circuit erroneously detects an overvoltage, the heating resistor 34b can be heated, preventing the thermal fuse 34a from blowing. Furthermore, with this configuration, even after the thermal fuse 34a has blown, the device can be reused by replacing the fuse unit 34'. On the other hand, while the lead member 50 according to the first embodiment requires only two terminals, the fuse unit 34' according to the second embodiment requires three terminals. [Industrial Applicability]

[0046] The power supply device and method of manufacturing the same according to the present invention can be suitably used as a backup power supply device that can be mounted on the power supply module of a computer server. It can also be suitably used as a backup power supply device for wireless base stations such as mobile phones, a power storage power supply for homes and factories, a power supply for street lights, a power storage device combined with a solar cell, a backup power supply for traffic lights, or a power supply for plug-in hybrid electric vehicles, hybrid electric vehicles, and electric vehicles that can switch between EV and HEV driving modes. [Explanation of symbols]

[0047] 100, 200…Power supply device 1... Secondary battery cell 2...Battery unit 3...Circuit unit 10...Battery holder 11...Placement surface 20...Reed plate 20H...Output lead plate 20G: Ground lead plate 21...Battery side intermediate terminal 21H...Battery side output 21G: Battery side ground 30...Battery side ground terminal 34...fuse module; 34'...fuse unit 34a...thermal fuse; 34b...heating resistor 40...Circuit board 41...Circuit side intermediate terminal 41H...Circuit side HIGH terminal 43...Control unit 43B...Second overvoltage protection circuit 44...Charging switching element 45...Discharge switching element 46...Circuit side ground terminal 47...External discharge terminal 48…External charging terminal 49...External terminal 50...Lead member 600…Power supply device 601...Secondary battery cell 602...Battery unit 603...Circuit unit 604...Circuit board 621H...Battery side total positive terminal 621G: Battery side ground terminal 634...Fuse module 634a...Thermal fuse 634b…Heating resistance 640...Connection terminal 641...Connection terminal 644...Charging switching element 645...Discharge switching element 646...Control unit 648...External terminal 649...External terminal 650... Heating resistor switching element DP...Discharge path CP: Charging and discharging path

Claims

1. a battery unit including a plurality of secondary battery cells connected in series and including a battery-side ground on a low-voltage side of the series-connected secondary battery cells and a battery-side output on a high-voltage side; a circuit unit electrically connected to the battery unit, controlling charging and discharging, and including an overvoltage detection fuse that detects an overvoltage and blows it; A method for manufacturing a power supply device comprising: With the detachable lead member connecting the overvoltage detection fuse and the battery side output removed, one or more battery-side intermediate terminals provided in the battery unit and electrically connected to intermediate potentials of at least some of the plurality of series-connected secondary battery cells; a step of connecting the terminals to one or more circuit-side intermediate terminals provided on the circuit unit; a step of fixing the lead member to the circuit unit and connecting the overvoltage detection fuse and the battery-side output; A method for manufacturing a power supply device comprising:

2. A method for manufacturing the power supply device according to claim 1, the circuit unit includes an overvoltage protection circuit that monitors an overvoltage of at least one of the plurality of secondary battery cells; The method for manufacturing a power supply device, wherein the overvoltage protection circuit is configured to blow the overvoltage detection fuse when an overvoltage of the secondary battery cell is detected.

3. a battery unit including a plurality of secondary battery cells connected in series and including a battery-side ground on a low-voltage side of the series-connected secondary battery cells and a battery-side output on a high-voltage side; a circuit unit connected to the battery unit; A power supply device comprising: the battery unit includes one or more battery-side intermediate terminals electrically connected to intermediate potentials of at least some of the plurality of series-connected secondary battery cells; The circuit unit includes: one or more circuit-side intermediate terminals connected to at least one of the plurality of secondary battery cells via the one or more battery-side intermediate terminals; an overvoltage detection fuse connected to the battery-side output, which detects an overvoltage of the plurality of secondary battery cells and blows out; a detachable lead member interposed between the overvoltage detection fuse and the battery-side output; A power supply device comprising:

4. 4. The power supply device according to claim 3, the circuit unit includes an overvoltage protection circuit that monitors overvoltage of the plurality of secondary battery cells; The power supply device is configured such that the overvoltage protection circuit blows the overvoltage detection fuse when it detects an overvoltage of the secondary battery cell.

5. 5. The power supply device according to claim 3 or 4, The power supply device wherein the lead member is formed of a metal bus bar.

6. 5. The power supply device according to claim 3 or 4, The power supply device wherein the lead member comprises a lead wire with a connector or a wire clip.

7. a battery unit including a plurality of secondary battery cells connected in series and including a battery-side ground on a low-voltage side of the series-connected secondary battery cells and a battery-side output on a high-voltage side; a circuit unit connected to the battery unit; A power supply device comprising: the battery unit includes one or more battery-side intermediate terminals electrically connected to intermediate potentials of at least some of the plurality of series-connected secondary battery cells; The circuit unit includes: one or more circuit-side intermediate terminals connected to at least one of the plurality of secondary battery cells via the one or more battery-side intermediate terminals; an overvoltage detection fuse connected to the battery-side output, which detects an overvoltage of the plurality of secondary battery cells and blows out; It is equipped with The overvoltage detection fuse is Two thermal fuses connected in series; a heating resistor having one end connected to the connection point of the thermal fuse and generating heat when energized to melt the thermal fuse; Equipped with The power supply device wherein the overvoltage detection fuse is configured as a unit that is detachable from the circuit unit.

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